Method and system for performing an infrared treatment

ABSTRACT

A method for performing an infrared treatment includes the steps of receiving an extruded product and feeding the extruded product to an oven including at least one lamp unit. The lamp unit includes a lamp, a reflective surface enclosing a first side of the lamp and positioned to direct radiation from the lamp, and a glass disposed between a second side of the lamp and an extruded product, wherein the glass separates the lamp and the extruded product. The method further includes the step of creating cross-linking between layers of the extruded product by directing the radiation at the extruded product. Still further, the method includes the steps of directing a first gas flow at a surface of the product and directing a second gas flow at the glass.

CROSS REFERENCE TO RELATED APPLICATION

This application is a continuation of U.S. patent application Ser. No.14/565928, filed on Dec. 10, 2015, now U.S. Pat. No. 9,475,236; which isa continuation of U.S. patent application Ser. No. 13/410,503, filedMar. 2, 2012, now U.S. Pat. No. 9,067,367. These prior applications areincorporated herein by reference in their entirety.

BACKGROUND OF THE INVENTION

The present invention relates generally to methods and apparatuses forperforming an infrared treatment, and more particularly, to methods andapparatuses for performing an infrared treatment on extruded plastic andelastomeric products in an infrared oven.

It is known in the prior art to heat plastic or elastomeric product thatcomes out of the extruder to cross-link the plastic or elastomericproduct to obtain a desired effect that changes the capabilities orproperties of the product (e.g., increases the strength of the product,changes the product to a solid, etc.). Furthermore, it is known toperform this heating of plastic or elastomeric product using infraredradiation and to use a wavelength of the radiation that penetratesinside the wall of the product in such a way that the heating takesplace at the same time in all the depths of the product.

One prior art method is disclosed in patent publication GB 2283 489. Inthis patent publication, the material is cross-linked by using infraredradiation in such a way that the temperature obtained by the radiationcorresponds to the wavelength demanded by the cross-linkage reaction.

A similar prior art method is presented in the patent publication FI109706. According to this method, an additional material or additivethat is used for modifying either physically or chemically theproperties of the plastic material is decomposed utilizing infraredradiation, wherein the wavelength is selected so that the radiationpenetrates through the plastic material itself as efficiently aspossible, but is also absorbed by the additional material, therebyheating and decomposing the additional material.

The greatest disadvantage of the prior art methods is that the infraredradiation inevitably consists of a distribution of differentwavelengths. It is also inevitable that a part of this wavelengthdistribution follows approximately part of the curve of Gauss, and thewavelength distribution has rays of long wavelengths that do notpenetrate into the material. Rather, the long wavelengths get absorbedby the surface of the product, causing inconvenient overheating of theproduct. Overheating causes the surface of the product to becomeoxidized or to react in some other unwanted way.

Attempts have been made to solve this problem. For example, U.S. Pat.No. 6,106,761 (“the '761 patent”) addresses these issues by eliminatingthe infrared rays that correspond to absorption peaks of the material tobe heated in order to minimize overheating of a surface of the material.The '761 patent notes that eliminating these rays may be accomplished byfiltering out the unwanted rays. The filtering process disclosed in the'761 patent is very difficult to undertake because, when filtering outcertain wavelengths, the filter itself gets overheated and becomes asource of infrared energy that sends the same filtered wavelength to thematerial, thus overheating the material.

One solution that attempts to avoid the overheating caused by filteringis cooling of the surface of the material during the infrared treatment.This can be done, for example, by blowing cool gas, like air, on thematerial. The greatest disadvantage of this method is that the air alsocools the infrared lamps and reduces the capacity of the lamps. Anotherdisadvantage is that dirt and other debris splashes from the material tothe lamps and, thus, the lamps get dirty, which again reduces thecapacity of the lamps.

It is very important for the irradiated material to be heated uniformlyacross an entire cross-section of the material. A method and apparatusfor performing an infrared treatment, for example, on plastic andelastomeric products, that overcomes all of the previous obstacles andthat uniformly heats the product is therefore desired.

SUMMARY OF THE INVENTION

According to one aspect of the present invention, a method forperforming an infrared treatment includes the steps of receiving anextruded plastic or elastomeric product and feeding the extruded plasticor elastomeric product to an oven including at least one lamp unit. Thelamp unit includes a lamp, a reflective surface enclosing a first sideof the lamp and positioned to direct radiation from the lamp, and aglass disposed between a second side of the lamp and an extrudedproduct, wherein the glass separates the lamp and the extruded product.The method further includes the step of creating cross-linking betweenthe layers of the extruded product by directing the radiation at theextruded product. Still further, the method includes the steps ofdirecting a first gas flow at a surface of the extruded product to coolthe surface of the extruded product and directing a second gas flow atthe glass at an intensity, direction, and temperature that prevents theglass from becoming an infrared source.

According to another aspect of the present invention, the oven includesa plurality of lamp units each including a plurality of lamps, areflective surface enclosing a first side of each lamp and positioned todirect radiation from the lamp into parallel rays of radiation, and aglass disposed between a second side of each lamp and an extrudedproduct, wherein the glass separates the lamp and the extruded product.Two lamps are positioned along a first axis and two lamps are positionedalong a second axis that is perpendicular to the first axis.

According to a further aspect of the present invention, the lamp isdisposed within a housing with the lamp being spaced from a first sideof the housing and the glass being disposed adjacent a second side ofthe housing. In another aspect, a third gas flow is provided through achannel in the housing for cooling components within the housing.

According to yet another aspect of the present invention, a system forperforming an infrared treatment on an extruded product includes atleast one lamp unit including a lamp and a reflective surface enclosinga first side of the lamp, wherein the reflective surface is positionedto direct radiation from the lamp. The lamp further includes a first gasflow directed at a surface of the extruded product for cooling theextruded product and a glass disposed between a second side of the lampand the extruded product, wherein the glass separates the lamp and theextruded product and prevents the first gas flow from hitting the lamp.A second gas flow is directed at a side of the glass facing the extrudedproduct for cooling the glass and preventing the glass from becoming aninfrared source.

A better understanding of the objects, advantages, features, propertiesand relationships of the invention will be obtained from the followingdetailed description and accompanying drawings which set forth anillustrative embodiment and which are indicative of the various ways inwhich the principles of the invention may be employed.

BRIEF DESCRIPTION OF THE DRAWINGS

For a better understanding of the invention, reference may be had to apreferred embodiment shown in the following drawings in which:

FIG. 1 is a side elevational view of a first embodiment of an apparatusfor performing an infrared treatment on a plastic or elastomeric productor material;

FIG. 2 is a cross-sectional view taken generally along the lines A-A ofFIG. 1 and showing a single infrared lamp unit; and

FIG. 3 is a magnified cross-sectional view of a portion of the infraredlamp unit of FIG. 2 and depicting in greater detail one housingcontaining an infrared lamp.

DETAILED DESCRIPTION

Turning now to the figures, wherein like reference numerals refer tolike elements, there is illustrated an apparatus or oven 100 forperforming an infrared treatment on a plastic or elastomeric product ormaterial. The apparatus performs the infrared treatment withoutfiltering of one or more wavelengths of the radiation.

Referring to FIG. 1, the apparatus in the form of an infrared oven orsystem 100 is equipped with six infrared lamp units 101. The infraredoven 100 is connected to an extruder (not shown) and extruded product102 is fed to the infrared oven 100 by the extruder. The extrudedproduct 102 may be fed from the extruder and redirected around a wheel103 or other transfer mechanism at an angle of about 90 degrees. Theextruded product 102 may be any type of extruded material in any shape.In one embodiment, the extruded material may be a plastic or elastomerictube. In other embodiments, the extruded product 102 is formed ofpolyethylene and/or includes one or more additional materials, such asadditives or cross-linking agents, as known in the art. One non-limitingexample of an additional material is a cross-linking peroxide, forexample an organic peroxide, which has to be heated to decompose and tocreate cross-linking. Another non-limiting example of an additionalmaterial is a chemical or physical foaming agent that releases gas uponheating to form foaming within the material.

A first set 104 of infrared units 101 includes three infrared units 101disposed adjacent one another on a first side 106 of the infrared oven100 and a second set 108 of infrared units 101 includes three infraredunits 101 disposed adjacent one another on a second side 110 of theinfrared oven 100. A feeding apparatus 112 is disposed between the firstand second sets 104, 108 of infrared units 101. The feeding apparatus112 includes any number of pulleys, gears, wheels, or other mechanismsthat aid in moving the extruded product 102 through the infrared oven100. The feeding apparatus 112 may additionally redirect the extrudedproduct 102, for example, at an angle of about 180 degrees. As can beseen in FIG. 1, the extruded product has a direction of travel 114. Thefeeding apparatus 112 is disposed between the sets 104, 108 of infraredunits 101 such that the first set 104 of infrared units 101 is disposedbefore the feeding apparatus 112 along the direction of travel 114 andthe second set 108 of infrared units 101 is disposed after the feedingapparatus 112 along the direction of travel 114. The positioning of thefeeding apparatus 112 allows the feeding apparatus 112 to provide theappropriate guidance to the extruded product through both sets 104, 108of infrared units 101. Once the extruded product 102 exits the secondset 108 of infrared units 101, the extruded product may again beredirected around a wheel 103 or other transfer mechanism at an angle ofabout 90 degrees.

The orientation and number of infrared units 101 as shown in FIG. 1 maybe varied, so long as the extruded product 102 is properly treated,i.e., the extruded product 102 is uniformly irradiated. For example,while FIG. 1 depicts six total infrared units 101, any number ofinfrared units 101 may be utilized. Further, although three infraredunits 101 are shown as being disposed prior to the feeding apparatus 112and three infrared units 101 are showing as being disposed after thefeeding apparatus 112, any number of infrared units 101 may be placedbefore or after the feeding apparatus 112. In addition, while the sets104, 108 of infrared units 101 are shown as being generally parallel,the sets 104, 108 may optionally be perpendicular, at any other anglewith respect to one another, or along a single axis. Additionally, anynumber of wheels, gears, or other transferring and/or redirectingmechanisms may be utilized to transfer and/or redirect the extrudedproduct 102 through the oven 100 and such transferring and/orredirecting mechanisms may be positioned at any point or points withinthe oven 100.

A single infrared unit 101 is depicted in detail in FIGS. 2 and 3,wherein each of the infrared units 101 may be similar in orientation andconstruction. The infrared unit 101 includes four infrared lamps 120formed in a circle. Two of the lamps 120 are disposed opposite oneanother along a first axis 122 and the other two of the lamps 120 aredisposed opposite one another along a second axis 124 with the firstaxis 122 and the second axis 124 being perpendicular. Each of the lamps120 is therefore disposed at an angle of about 90 degrees about acenterpoint 126 of the unit 101 with respect to an adjacent lamp 120.Each lamp 120 is disposed within a separate housing 130. Although fourlamps 120 are depicted in FIG. 2, any number of lamps 120 that woulduniformly irradiate the extruded product 102 and irradiate the extrudedproduct 102 from all sides may be utilized. One or more of the infraredunits 101 may be different in orientation or construction from the otherinfrared units 101. For example, the number or location of the lamps 120may be varied.

When the lamps 120 are activated and the oven 100 is in operation, eachof the lamps 120 sends rays 140 of infrared radiation (only some of therays 140 are labeled) toward the product 102. In one embodiment, therays 140 are parallel, which adds flexibility to the overall systembecause tubes with different dimensions may be irradiated without theneed to adjust the system. Some of the rays 140 penetrate through asurface 142 of the product, hit the additional material that isvibrating with the same frequency, change into heat, and cause across-linking reaction. As with the prior art, the wavelengths that arelonger cannot penetrate the surface 142 of the extruded product 102 and,thus, the longer wavelengths are converted into heat and causeunfavourable heating of the surface 142 of the extruded product 102. Itis therefore necessary to cool the extruded product 102 by directing agas or air flow 143 onto the surface 143 of the extruded product 102.The gas flow 143 may be directed, in this example, between the housing130 and the surface 142 of the extruded product 102 from a side 144 ofthe unit 101 (FIG. 1). Heat-resistant glass 150 is installed betweeneach of the lamps 120 and the extruded product 102 to protect the lamps120. In particular, the glass 150 prevents the gas flow 143 from hittingthe infrared lamps 120 and prevents dirt or other debris from movingfrom the extruded product 102 to the lamps 120, while still allowingcooling of the surface 142 of the extruded product 102. The gas flow143, or any of the gas flows disclosed herein, may be air, nitrogen, orany other gas flow sufficient for cooling. If an air flow is utilized,the air flow may be at ambient temperature and an intensity of an airflow would depend upon production speeds and the amount and level ofinfrared radiation.

The gas flow 143 can be directed to hit mainly the extruded product 102and a second gas flow 152 may be arranged to impinge upon the sides ofthe glasses 150 facing the extruded product 102 to cool the glasses 150and prevent the glasses 150 from emitting radiation that heats thesurface 142 of the extruded product 102. It is possible to separatelyregulate the gas flows 143, 152 (e.g., by independent switches) and,thus, it is possible to regulate each of the gas flows 143, 152 (e.g.speed, temperature) independently from each other, if necessary. It isalso possible to have separate gas flows and regulation for each of thedifferent glasses 150 within a lamp unit 101. While the gas flows 143,152 are disclosed as being flows of gas or air, the gas flows 143, 152may each alternatively be one or more flows of any type or types of gassuitable for cooling an extruded material.

The direction of the gas flow 143 to the extruded product 102 may befrom above downwards, from below upwards or some other direction,depending on the orientation of the infrared unit 101 and/or the oven100. The amount of gas flow 143 may be regulated for the variousinfrared units 101. For example, the amount of gas flow 143 may beincreased from a first of the infrared units 101 to a last of theinfrared units in a process direction 160, as a temperature of theextruded product 102 generally increases in the process direction 160.Optionally, any other variation of gas flow 143 that produces a desiredproduct may be implemented. Likewise, the gas flow(s) 152 that are usedto cool the glasses 150 may be regulated differently in differentinfrared units 101 to correspond with the different needs of cooling ofthe different glasses 150 at different stages of the process.

Because some radiation from the infrared lamps 120 can get absorbed bythe glasses 150, the glasses 150 can sometimes become sources ofinfrared radiation and begin sending radiation toward the surface 142 ofthe extruded product 102. As noted above, the gas flows 143 and 152 areregulated in speed, temperature, direction, etc. so that they cool boththe surface of the product 102 and the glasses 150, respectively. Thegas flows 143, 152 are regulated so that the surface 142 of the extrudedproduct 102 does not react unfavourably (e.g., a burning smell is notcreated) and the glasses 150 do not emit infrared radiation.

Referring to FIG. 2, each of the housings 130 includes a reflectivesurface 160 generally enclosing a first side 162 of each of the lamps120. The reflective surfaces 160 may be coated with gold, but mayalternatively be coated with one or more other reflective materials.Each reflective surface 160 may have a shape that directs all of therays of infrared radiation 140 emitted from a respective lamp 120 alongparallel paths within the housing 130 and toward the extruded product102. The parallel paths are also generally parallel to the axis 122 or124 along which the respective lamp 120 is disposed. Any rays 140 ofinfrared radiation from opposite lamps 120 are also directed back in thedirection from which they came by an opposing reflective surface 160.

As best seen in FIG. 3, a channel 180 is provided for guiding a thirdgas flow 182 (FIG. 3) through the housing 130. The third gas flow 182may be utilized to cool and prevent damage to cabling inside the housingand/or other sensitive components disposed within the housing 130. Aswith the gas flows 143, 152, the gas flow 182 may include any type ortypes of gas flow that suitably cool the components within the housing130.

To ensure that the infrared oven 100 of the present invention functionsin the desired manner, a series of tests were conducted using theprinciples of the invention. A plastic tube having an outside diameterof 16 mm and a wall thickness of 2 mm was extruded utilizing methodsknown in the prior art. The tube was produced using high densitypolyethylene with a high molecular weight and before the extrusion,0.45% of organic peroxide was mixed with the high density polyethylene.Immediately after extrusion of the tube, the tube was heated by theinfrared radiation so that the heating length of the tube was 960 mm,the tube stayed in the oven for 6 seconds, the infrared efficiency was36 kW, and the average wavelength of the infrared radiation was 1.6micrometers. The temperature of the surface of the tube and in themiddle of the wall immediately after the extrusion was 162° C.

Four tests were conducted and, in each case, the temperatures of amiddle of the wall of the tube (T1) and the surface of the tube (T2)were measured after the infrared heating and the results are listed inthe following chart:

Test T1 Temperature T2 Temperature Test 1, no insulating 210° C. 310° C.glass, no gas flow Test 2, insulating 210° C. 340° C. glass, no gas flowTest 3, no insulating 195° C. 200° C. glass, gas flow Test 4, insulating210° C. 200° C. glass, gas flow

It can be seen from the results that the most balanced result isachieved with the arrangement of Test 4 where the gas flow cools boththe surface of the tube and the insulating glass. This arrangementcorresponds with the method according to the present invention. In Test3, the gas flow also cooled the infrared source and, therefore, themeasurement in the middle of the tube remained lower than in Test 4.

The method of using the oven 100 of the present invention to perform aninfrared treatment on an extruded plastic or elastomeric product allowsfor cooling of the surface 142 of the extruded product 102 withoutdecreasing the efficiency of the lamps 101. In particular, the extrudedproduct 102 is transported from an extruder to the oven 100 and enters afirst side of the oven 100. The extruded product 102 then proceedsthrough a number of lamp units 101, each lamp unit 101 including atleast one lamp 120, a reflective surface 160 enclosing a first side ofthe lamp 120 and positioned to direct radiation from the lamp intoparallel rays 140 of radiation, and a glass 150 disposed between thesecond side of the lamp 120 and the extruded product 102. The glass 150separates the lamp 120 and the extruded product 102. The method furtherincludes the steps of directing the extruded product 102 through theoven 100, directing the parallel rays of radiation at the extrudedproduct 102 to create cross-linking between layers of the extrudedproduct 102. A first flow of cooling gas 143 may be directed at asurface 142 of the extruded product 102 and a second flow of cooling gas152 may be directed at the glass 150 for cooling the glass 150. Thecooling gas 152 is focused at an intensity, direction, and temperaturethat prevent the glass 150 from becoming an infrared source and theglass 150, again, prevents the gas flows 143, 152 from hitting andcooling the lamps 120.

While specific embodiments of the invention have been described indetail, it will be appreciated by those skilled in the art that variousmodifications and alternatives to those details could be developed inlight of the overall teachings of the disclosure. For example, differentmaterials possessing similar characteristics may be used and thepositioning of each of the layers with respect to one another may bechanged. Accordingly, the particular arrangement disclosed is meant tobe illustrative only and not limiting as to the scope of the inventionwhich is to be given the full breadth of the appended claims and anyequivalents thereof

What is claimed is:
 1. A method for performing an infrared treatment inan infrared oven, the method comprising the steps of: receiving anextruded plastic or elastomeric product; feeding the extruded plastic orelastomeric product to an oven having at least one lamp unit, the atleast one lamp unit including a lamp, a reflective surface enclosing afirst side of the lamp and positioned to direct radiation from the lamp,and a glass disposed between a second side of the lamp and an extrudedproduct, wherein the glass separates the lamp and the extruded product;creating cross-linking between layers of the extruded product bydirecting the radiation at the extruded product; preventing the glassfrom becoming an infrared source by directing a gas flow at the glassbetween the glass and the extruded product; and wherein the gas flow isnot in fluid communication with the lamp.
 2. The method of claim 1,further including the step of providing a plurality of lamp units eachhaving four lamps, wherein two of the lamps are disposed along a firstaxis and the other two lamps are disposed along a second axisperpendicular to the first axis.
 3. The method of claim 2, furtherincluding the step of providing glass disposed between each of the fourlamps and the extruded product.
 4. The method of claim 3, wherein eachof the lamps is disposed within a housing with the lamp being spacedfrom a first side of the housing and the glass being disposed adjacent asecond side of the housing.
 5. The method of claim 4, further includingthe step of providing second gas flow through a channel on the firstside of the housing.
 6. The method of claim 5, wherein the second gasflow is not directed at the lamp or the surface of the product.
 7. Themethod of claim 1, further including the steps of providing the extrudedplastic or elastomeric product as a tube and cooling a middle of a wallof the tube to a temperature of about 210° C.
 8. The method of claim 8,further including the step of cooling a surface of the tube to atemperature of about 200° C.
 9. A method for performing an infraredtreatment in an infrared oven, the method comprising the steps of:receiving an extruded product; feeding the extruded product to an ovenhaving a plurality of lamp units, each lamp units including a pluralityof lamps, a reflective surface enclosing a first side of each lamp andpositioned to direct radiation from the lamp into parallel rays ofradiation, and a glass disposed between a second side of each lamp andan extruded product, wherein the glass separates the lamp and theextruded product; positioning two lamps along a first axis and two lampsalong a second axis that is perpendicular to the first axis; creatingcross-linking between layers of the extruded product by directing theparallel rays of radiation at the extruded product; directing a firstgas flow at a surface of the extruded product to cool the extrudedproduct; directing a second gas flow at the glasses at an intensity,direction, and temperature that prevents the glasses from becominginfrared sources; wherein the first and second gas flows are not influid communication with either of the lamps; and supplying a third gasflow into the housing through a channel on the first side of thehousing.
 10. The method of claim 9, wherein the first and second gasflows are isolated from one another.
 11. A method of cooling a plasticor elastomeric product in a cross-linking process, the method includingthe steps of: receiving an extruded plastic or elastomeric product;feeding the extruded plastic or elastomeric product to an oven having atleast one lamp unit, the least one lamp unit including a housing inwhich is disclosed a lamp positioned to direct radiation at the plasticor elastomeric product; directing a first air at the glass between theglass and the extruded product; directing a second air flow into thehousing that holds the at least one lamp to provide a cooling effectwithin the housing; and wherein the first and second air flows areseparate air flows that are isolated from one another.
 12. The method ofclaim 11, further including the steps of providing the extruded productas a plastic or elastomeric tube and cooling a middle of a wall of thetube to a temperature of about 210° C.
 13. The method of claim 11,further including the step of cooling a surface of the tube to atemperature of about 200° C.
 14. The method of claim 11, wherein thesecond gas flow is supplied through a channel on the first side of thehousing.
 15. The method of claim 14, wherein the second gas flow is notdirected at the lamp or the surface of the product.